Self-cleaning flooring system

ABSTRACT

A self-cleaning flooring system is provided that includes at least one module. The module comprises a drain pan, a plurality of discharge ports, and at least one side wall. The drain pan may have a ramp and a drain outlet. The ramp may slope downward towards the drain outlet. The discharge ports may be disposed about a periphery of the drain pan and may be directed towards the drain outlet to direct flushing fluid towards the drain outlet. The side wall may circumscribe a portion of the periphery of the drain pan and include a hollow passage and at least one fluid inlet. The fluid inlet may be in fluid communication with the hollow passage for delivering flushing fluid to the discharge ports.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of co-pending U.S.application Ser. No. 10/282,393, filed Oct. 29, 2002, and co-pendingU.S. application Ser. No. 11/074,814, filed Mar. 8, 2005, the entirecontents of which are hereby incorporated by reference.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND

The present invention relates generally to flooring protection and, moreparticularly, to a self-cleaning flooring system having modules whichare interconnectable to horizontally adjacent modules to form acontinuous flooring system for catching waste products in a variety ofapplications and industries including, but not limited to, laundryfacilities and food preparation facilities. The flooring system of thepresent invention may also be formed as a permanent installation that iscast in a concrete floor using removable male mold inserts thatduplicate the shape of a drain pan and over which floor grids may beinstalled for supporting personnel standing thereupon.

Advantageously, the flooring system of the present invention is adaptedfor use in dairies, meat processing plants, stables, poultry operations,machine shops, clean assembly rooms, printing facilities, and foodprocessing plants. Furthermore, the flooring system of the presentinvention may be used in transition areas in animal processingapplications. For example, the flooring system of the present inventionmay be used between a feed yard and dairy milking stations whereinhooves of livestock passing over the flooring system could be sprayedprior to entering the dairy milking station such that undesirableresidue (e.g., manure) may be washed from the livestock hooves and intothe flooring system for later retrieval as fertilizer.

In many industries, cleanliness of certain facilities and rooms iscritical. For example, in the food preparation industry, sanitation andcleanliness in the kitchen is a major concern. The kitchen flooring inrestaurants, hotels, institutions, and commercial food vendingfacilities in general is subject to frequent spillage from wasteproducts. Such waste products may be in the form of spilled liquids,semi-solids, and small solids and may include grease, oil, water, and aninfinite variety of food products. Spilled waste products may create asanitation hazard as a hot kitchen is a natural breeding ground forharmful bacteria that may be caught in tile grout, and around pipes,drains or other kitchen fixtures. Because of the immovable nature ofsuch kitchen fixtures, cleanliness is difficult if not impossible tomaintain. Stringent health codes in most states require that kitchens incommercial food vending facilities receive daily cleaning.

Daily cleaning of walls, counter tops, appliances and floors involves agreat deal of hand labor consuming a considerable amount of time. Inaddition, the waste products may create a health hazard in that spilledfood products are often wet or sticky, creating a high risk that kitchenpersonnel may be injured in a fall. Furthermore, spilled grease or oilcreates a fire safety hazard requiring the cessation of all operationsin the kitchen until the grease or oil is removed from the floor. As maybe expected, shutting down all kitchen operations in a restaurant orhotel may result in a significant loss of revenue. In addition, currentcleaning methods of facilities such as commercial kitchens may entailthe temporary removal and/or dismantling of certain equipment andflooring systems followed by lengthy washing with water. As may beappreciated, such cleaning methods results in the use of largequantities of water which may increase water conservation issues incertain locales.

There is currently known in the prior art flooring systems that areconfigured to address sanitation and safety concerns. One prior artdevice comprises a washable floor for collecting waste. The deviceprovides a grid or mesh on which a person may stand, the grid mountedabove a sub-floor onto which waste falls. The sub-floor is downwardsloping towards a drain outlet. Flushing means are provided for flushingthe fluid waste down the sub-floor towards the drain outlet. The grid ispivotably movable between a horizontal position and a vertical positionand is removable to facilitate maintenance. Although the deviceaddresses a few safety and sanitation issues mentioned above in that itprovides a disposal means for fluid waste, the device lacks installationflexibility in that it must be custom fitted to a particular floorconfiguration. In addition, the size of the grids and sub-floor are suchthat these components are too heavy and too large to be individuallywashed, either by hand or by mechanical means, such as in a commercialdishwasher.

Another prior art device provides a supporting surface for personnelstanding thereupon. The device allows water or fluid to flow through thesupporting surface and underneath a modular flooring member. The deviceincludes a series of cross-channels forming a gridwork of fluid padswhich permit water to flow underneath the modular flooring. However, amajor drawback to the device is that a large portion of the subsurfaceof the flooring member is in direct contact with the moist supportfloor. Although this device addresses some safety concerns in that itprovides a non-slip surface upon which personnel may stand, the deviceis subject to the problems of mildew and degradation of the subfloorarising from captured water. Furthermore, the device is not configuredto be easily washable by hand or by mechanical means. Finally, theabove-mentioned devices require the use of large amounts of water forthorough cleaning thereof.

As can be seen, there exists a need in the art for a flooring system forcatching waste products that also provides a non-slip surface upon whichpersonnel may stand to reduce the risk of injury from slipping.Furthermore, there exists a need in the art for a flooring system thatis self-cleaning such that waste products may be flushed toward a drainoutlet for subsequent disposal. Additionally, there exists a need in theart for a flooring system that is light weight and of small size suchthat it is removable for easy cleaning by hand or with cleaningequipment such as a commercial dishwasher as may be found in acommercial kitchen.

Also, there exists a need in the art for a flooring system that ismodular such that individual modules may be interconnected to cover adesired area in a variety of applications and industries including, butnot limited to, laundry facilities and food preparation facilities suchas a cooking line in a commercial kitchen. Finally, there exists a needin the art for a flooring system that may be permanently molded into aconcrete floor using removable male mold inserts that duplicate theshape of a drain pan and over which floor grids may be installed forsupporting personnel standing thereupon. Such a flooring system may beused in various industries including, but not limited to, dairies,stables and meat processing plants.

BRIEF SUMMARY

The present invention specifically addresses and alleviates the abovereferenced deficiencies associated with flooring systems. Moreparticularly, the present invention is an improved self-cleaningflooring system for catching waste products. In one embodiment, theflooring system is modular and is configured such that it may be cleanedusing cleaning equipment that is typical of the industry wherein theflooring system is installed. For example, if the flooring system isinstalled in a commercial kitchen, the flooring system is adapted to becleaned using commercial dishwashing equipment. In another embodiment,the flooring system may be cast-in-place into a concrete substrate usingfoam inserts such that upon curing of the concrete, removal of the foaminserts, installation of plumbing, and laying of floor grids, a durableflooring system is provided.

In accordance with an embodiment of the present invention, there isprovided a self-cleaning flooring system for catching waste products.The flooring system has at least one module comprised of a drain pan anda floor grid. The drain pan includes a pair of ramps and a drain channelcentrally located between the ramps. The drain pan may include a pair ofside walls and a pair of end walls. The ramps are disposed on oppositesides of the drain channel and slope downwardly towards the drainchannel. The drain channel extends between the end walls and slopesdownwardly from one end of the drain pan toward an opposite end of thedrain pan toward a drain outlet. The side and end walls collectivelyform a periphery of the drain pan and extend upwardly from the ramps anddrain channel to enclose the drain pan. The side walls and/or ramps haveat least one, and, preferably, a plurality of discharge mechanisms suchas discharge ports and/or spray nozzles for releasing flushing fluidonto the ramp such that waste products that fall onto the ramps arewashed toward the drain channel.

The floor grid is configured to support personnel and/or animalsstanding upon or moving thereacross while permitting waste products topass therethrough. The side wall may include a hollow passage having afluid inlet whereby flushing fluid may be delivered to the dischargeports. The fluid inlet of adjacent ones of the modules also allows forthe flushing fluid to flow therebetween. The end most one of the modulesmay be connectable to the flushing fluid source. The fluid inlet may beconnected to a fluid supply wherein flushing fluid is delivered to thehollow passage. An overflow passage may be provided near the drainchannel for allowing the flow of flushing fluid and/or liquid wasteproducts between adjacent modules. The floor grid may comprise aplurality of abutting floor grids disposed parallel to one another. Thefloor grids are sized such that the length of the module matches thecombined length of the abutting floor grids. The module may include aplurality of dowels with the side walls having complimentary aperturessized for receiving the dowels for interconnecting the modules.

The desired number of drain pans are assembled horizontally and joinedusing dowels or other suitable means. The fluid inlets are connected tothe flushing fluid source. During use, the flushing fluid flows from thefluid inlets into the drain pans. The flushing fluid may be provided ona periodic basis through the use of a timed control valve. Alternately,the flushing fluid may be manually provided as desired when theaccumulation of waste products on the ramps reaches a critical level.Additionally, a thermal sensor may operate to provide the flushing fluidto the fluid inlet in the case of a fire. The flushing fluid may be inthe form of water from a tap water source, and is discharged out of thedischarge ports. The flushing fluid may be pressurized and the flushingfluid may include additives such as degreasers to facilitate breakdownof certain food substances.

Waste products that fall through the floor grid are washed by theflushing fluid down the ramps toward the drain channel. Once in thedrain channel, the flushing fluid then washes the waste products towardthe drain outlet. Removable strainer trays may be used over the drainchannel to prevent waste products from entering the drain channel. Drainbaskets may be installed over the drain outlet to prevent waste productsfrom washing down the drain outlet. Floor grids may be installed overthe drain pan to support personnel standing or working above the drainpans. The floor grids are preferably sized and configured to preventwaste products of a predetermined size from entering the drain pan.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the various embodimentsdisclosed herein will be better understood with respect to the followingdescription and drawings, in which like numbers refer to like partsthroughout, and in which:

FIG. 1 is a perspective view of a first embodiment of a flooring systemillustrating the connective relationship of horizontally adjacentmodules that may make up the flooring system;

FIG. 2 is an exploded perspective view of the flooring system of FIG. 1illustrating a module and the relationship of a drain pan and floorgrids that make up the module;

FIG. 3 is a longitudinal sectional view of the module taken along line3-3 of FIG. 1 illustrating ramps sloping downwardly toward a drainchannel;

FIG. 4 is an enlarged partial sectional view of the module taken fromFIG. 3 illustrating the connective relationship of a spray nozzledisposed within a side wall of the module;

FIG. 5 is a transverse sectional view of the module of the firstembodiment taken along line 5-5 of FIG. 1 illustrating the drain channelsloping downwardly toward a drain outlet;

FIG. 6 is a perspective view of a second embodiment of the flooringsystem illustrating the connective relationship of floor grids andhorizontally adjacent drain pan sections that make up a drain panassembly;

FIG. 7 is an exploded perspective view of the flooring system of FIG. 6illustrating the connective relationship of a first and a second rampsection with a channel section that make up the drain pan section of thesecond embodiment;

FIG. 8 is a block diagram of a pressure tank and timer connected to themodules of the present invention;

FIG. 9 is a perspective view of the flooring system wherein the drainpan includes a drain channel that is singly-sloped toward the drainoutlet located at one end of the drain pan;

FIG. 10 is a cross-sectional view of the module taken along line 10-10of FIG. 9 and illustrating a the drain pan installed in a concretesubstrate wherein the drain pan includes a perimeter flange formed abouta periphery of the drain pan to support the drain pan;

FIG. 11 is a top view of the module shown in FIG. 9 illustrating anarrangement of the spray nozzles installed in the ramps;

FIG. 12 is a side view of the module of FIG. 9 illustrating the drainchannel sloping from one end of the drain pan to the other toward thedrain outlet;

FIG. 13 is a partial cross sectional view of the flooring system in afurther embodiment wherein the drain pan is cast-in-place into aconcrete substrate and illustrating a manifold disposed above one of theramps and to which spray nozzles may be fluidly connected;

FIG. 14 is a schematic diagram of a plumbing system in an embodimentwherein the plumbing system is interconnected to a series of spraynozzles installed in a single section of the flooring system; and

FIG. 15 is a schematic diagram of a plumbing system in anotherembodiment wherein the plumbing system is interconnected to a dualsection of the flooring system.

DETAILED DESCRIPTION

The present invention will now be described in particular with referenceto the accompanying drawings. FIGS. 1 and 2 show a module 12 of thefirst preferred embodiment of a flooring system 10 for catching wasteproducts. FIG. 1 is a prospective view of the first embodiment of theflooring system 10 illustrating the connective relationships ofhorizontally adjacently disposed modules 12 that make up the flooringsystem 10 illustrating the module 12 and the relationship of a drain pan14 and floor grids 24 that make up the module 12 of the firstembodiment.

Although FIGS. 1 and 2 show the module 12 as having three of the floorgrids 24 disposed upon the drain pan 14, it is contemplated that themodule 12 may include at least one or any number of floor grids 24.Preferably, such floor grids 24 will collectively be sufficient to coverthe drain pan 14. The drain pan 14 is shown in the figures as having agenerally rectangular shape. However, the drain pan 14 may be configuredin any number of shapes and sizes. Preferably, the drain pan 14 isconfigured such that the modules 12 may be interconnected to one anotherin a horizontally aligned manner. Each one of the drain pans 14 may havea square shape with the floor grid 24 being sized and configuredcomplementary to the shape of the drain pan 14.

Referring still to FIGS. 1 and 2, as can be seen, the drain pan 14includes a drain channel 40, a pair of ramps 16, a pair of side walls 26and a pair of end walls 42. The ramps 16 are disposed on opposite sidesof the drain channel 40 along the length of the drain channel 40. As canbe seen in FIG. 2, the ramps 16 are oriented to slope downwardly along adirection indicated by the arrows (i.e., towards the drain channel 40).The drain channel 40 is interposed between the side walls 26 and extendsbetween the end walls 42.

The drain channel 40 itself may be configured to slope downwardly fromone end of the drain pan 14 to the opposite end of the drain pan 14toward a drain outlet 18. The drain outlet 18 may be connected to adrainage or sewage system of the facility within which the flooringsystem 10 is installed. A removable drain basket 78 may be provided withthe flooring system 10 and may be installed over the drain outlet 18 forpreventing solids or semisolid waste products of a predetermined sizefrom entering the drain outlet 18. Alternatively, or in conjunction withthe drain basket 78, an elongate, flat filtering mesh 62 may be providedalong the length of the drain channel 40, (shown only in FIG. 2), toprovide an additional measure of filtering of waste products.

As shown in FIG. 2, the drain channel 40 may slope downwardly toward thecentralized drain outlet 18 positioned midway along the drain channel40. In this regard, the drain channel 40 may have two separate slopingsurfaces that slope toward one another toward the centrally locateddrain channel 40. However, the configuration of the drain pan 14 whereinthe drain channel 40 has only the single sloping surface is preferred.In this configuration, the drain channel 40 slopes downwardly from oneof the end walls 42 of the drain pan 14 toward the other one of the endwalls 42 of the drain pan 14.

The drain outlet 18 is preferably positioned adjacent to one of the endwalls 42. The end walls 42 as well as the side walls 26 extend upwardlyfrom the ramps 16 to enclose the drain pan 14. Likewise, the end walls42 also extend upwardly from the drain channel 40 to provide enclosureto the drain pan 14. Provided in each one of the ramps 16 may be aplurality of discharge ports 22 which are specifically configured forreleasing or spraying flushing fluid onto the ramps 16 such that wasteproducts are washed down the ramp 16 toward the drain channel 40.

As was earlier mentioned, floor grids 24 may be mounted atop each one ofthe drain pans 14. In order to enhance removability and to facilitatewashing and cleaning of the floor grids 24, the floor grids 24 may beprovided in reduced sizes (i.e., widths) such that a plurality of floorgrids 24 disposed in abutting relationship to one another are requiredfor covering one of the drain pans 14. For example, as is shown in FIG.2, three of the floor grids 24 are required in order to completely coverthe drain pan 14.

The floor grids 24 are preferably appropriately sized and configured tosupport personnel, animals or other loads placed thereupon whilepermitting waste products to pass therethrough. The floor grids 24 aresupported at the periphery of the drain pan 14 and may be specificallymounted on the side walls 26 such as along the grid support notches 82extending along the length of each one of the side walls 26. In thisregard, the floor grids 24 extend across the ramps 16 and the drainchannel 40 and may be supported by the side walls 26. Optionally, gridsupport notches 82 may also be provided along each one of the end walls42 such that the end most ones of the floor grids 24 may be supported bythe grid support notches 82 along the end walls 42.

Although the figures show the drain pan 14 having side walls 26, it iscontemplated that the module 12 may be comprised of a drain pan 14having a single one of the ramps 16 that extends or wraps around thedrain pan 14. In such an arrangement, the ramp 16 defines the drain panperiphery 20 from where it slopes downwardly toward the drain channel40. Alternatively, the drain pan 14 may be configured such that the ramp16 slopes downwardly towards the drain outlet 18. The drain panperiphery 20 may have a plurality of the discharge ports 22 spacedtherealong for spraying flushing fluid onto the ramp 16.

In one embodiment, each one of the side walls 26 may include a hollowpassage 28 formed therealong and through which flushing fluid may flow.A fluid inlet 30 may be provided in at least one of the end walls 42 aswell as in the side walls 26 and is configured to provide flushing fluidto the ramps 16 via the hollow passages 28. Alternatively, inembodiments that omit the hollow passage 28, the flushing fluid mayenter the fluid inlet 30 and may be provided directly to the ramps 16.However, the fluid inlet 30 may provide a conduit through which amanifold 94 may pass and which carries flushing fluid to the dischargeports 22 or spray nozzles 32.

As can be seen in FIG. 1, the self-cleaning flooring system 10 of thepresent invention may be comprised of a plurality of the modules 12 witheach one of the modules 12 being configured to be connectable to oneanother in horizontal alignment. Interconnectablity of the modules 12 isfacilitated through the use of mechanical fixtures such as, for example,a dowel 36 and aperture 38 system wherein dowels 36 are provided in oneof the modules 12 and into which may be received by apertures 38 formedin an adjacent one of the modules 12.

However, it will be appreciated that the module 12 may be interconnectedto one another through a variety of attachment mechanisms and is notlimited by the specific embodiments or configurations shown anddisclosed herewithin. As shown in FIG. 2, the module 12 may include atleast one strainer tray 74 which may be configured to extend along thelength of the drain channel 40 and which may be mounted above the drainchannel 40. The strainer tray 74 is preferably configured to fit withinthe drain channel 40 and is operative to prevent waste products of apredetermined size from entering the drain channel 40.

As can be seen in FIG. 2, the strainer tray 74 extends along the lengthof the drain channel 40 and is specifically adapted to complement thedual sloped surface of the drain channel 40. In this regard, thestrainer tray 74 has a middle thickness which is larger than thethickness at the free ends of the strainer tray 74. The strainer tray 74may additionally include a grate 76 that acts as a filtering mechanismto prevent waste products from passing into the drain channel 40. Forconfigurations wherein the drain channel 40 is configured as a singlesloping surface sloping downwardly toward the drain outlet 18 at an endof the drain pan 14, the strainer channel is preferably configuredcomplimentary thereto. More specifically, the strainer tray 74 ispreferably configured to be thicker at one end than at an opposite endsuch that the grate 76 mounted atop the strainer tray 74 is disposed ingeneral horizontal orientation when installed in the drain channel 40.

Turning now to FIGS. 9-12, shown is a self-cleaning flooring system 10of the present invention in an embodiment that may be installed on asubstrate 88 such as a concrete substrate 88. As can be seen in FIG. 10,the drain pan 14 may be installed on a setting bed of dry packedconcrete although the drain pan 14 may be installed on a substrate 88 ofany composition. The periphery of the drain pan 14 may include aperimeter flange 80 extending therearound which acts as a ledge uponwhich the drain pan 14 may be supported. The perimeter flange 80 extendslaterally outwardly from side walls 26 of the drain pan 14. Preferably,the perimeter flange 80 is installed so as to be even with floor level86. More specifically, the perimeter flange 80 of the drain pan 14 ispreferably installed to be flush with an upper surface of the floorcovering 84 at the floor level 86 such as floor tile or other floorcoverings 84.

As can be seen in FIG. 10, the ramps 16 of the drain pan 14 may beinstalled on the substrate 88 such as the concrete substrate 88 whichmay, in turn, be installed over a base surface such as a grading 90 ofearthen or soil. The setting bed then may be in turn laid atop theconcrete substrate 88 and may be comprised of dry packed concrete. Thefloor covering 84 such as floor tile may be then, in turn, installedover the setting bed. The perimeter flange 80 may be installed over thesetting bed and is preferably level with the floor level 86.

The embodiment of the flooring system 10 shown in FIGS. 9-12 is similarin configuration to that which is shown in FIGS. 1-2 and which isdescribed above. More specifically, the drain pan 14 as shown in FIGS.9-12 may be comprised of a pair of opposing ramps 16 that slopedownwardly toward a drain channel 40. However, it is contemplated thateach one of the modules 12 may be comprised of a drain pan 14 havingonly one ramp 16 with a drain outlet 18 disposed in a corner of thedrain pan 14. The ramp 16 may slope downwardly toward the drain outlet18. However, it is believed that the configuration shown in FIGS. 1 and2 and FIGS. 9-12 is preferable wherein the drain pan 14 is comprised ofa pair of ramps 16 disposed on opposite sides of the drain channel 40.The drain channel 40, as described above, is sloped downwardly towardthe drain outlet 18 which is located adjacent to the end wall 42.

Referring still to FIG. 10, as can be seen, the opening formed in thesubstrate 88 and setting bed is sized to be slightly larger than thedrain pan 14. More specifically, the opening includes areas into whichplumbing (such as a manifold 94 for carrying flushing fluid), may beinstalled after curing of the concrete. Once the plumbing is installed,the drain pan 14 can be installed with portions of the ramp 16 restingupon the substrate 88.

The drain pan 14 may then be supported at the periphery thereof byinstallation of the dry packed concrete which forms the final settingbed. In this regard, the dry packed concrete fills voids underneath theside wall 26 and perimeter flange 80. The drain pan 14 may be checkedfor levelness to ensure proper functioning and flowing of the flushingfluid during operation of the flooring system 10. It is contemplatedthat reinforcement bar may be provided to assist in leveling of thedrain pan 14 prior to installation of the setting bed.

It is contemplated that the drain pan 14 may be installed in multi-floorbuildings wherein steel decking may be utilized as the substrate 88. Inthis regard, the drain pan 14 can be accommodated with appropriatecutouts to allow fitment and support of the drain pan 14 on the steeldecking. The flooring system 10 of the present invention may beinstalled similar to the method for installing a floor sink or trough.Mounting straps may be secured to the decking prior to pouring ofconcrete which, in turn, occurs prior to installation of the drain pan14. As was earlier mentioned, it is preferable that the drain pan 14 ischecked for levelness prior to pouring or curing of the concrete.

Following installation of the manifold 94 and installation of the drainpan 14, the appropriate number of discharge ports 22 such as spraynozzles 32 may be fluidly connected to the manifold 94 such thatflushing fluid passing through the manifold 94 may be discharged out ofthe spray nozzles 32. As can be seen in FIG. 11, three of the spraynozzles 32 are provided on opposite sides of the drain pan 14 and areextended through the ramp 16 portions thereof. The spray nozzles 32 maybe threadably connected to the manifold 94. Although three of the spraynozzles 32 are shown on each side of the drain pan 14, any number may beprovided.

Furthermore, although the spray nozzles 32 are shown in FIG. 10 asextending through a crease or slope-change in the ramp 16, it iscontemplated that the spray nozzles 32 may be installed anywhere alongthe ramps 16. Furthermore, although the ramp 16 shown in FIG. 10 has adoubly-sloped surface, it is contemplated that the ramp 16 may beprovided with a singly sloped surface extending from the side wall 26down to the drain channel 40. Additionally, it is contemplated that theramp 16 may be curved or have a multiply angled or sloped surface.However, it is believed that the single or doubly sloped surface ispreferred in order to enhance the washing of the waste products down theramp 16 toward the drain channel 40.

Referring to FIG. 3, shown is a longitudinal sectional view of themodule 12 taken along line 3-3 of FIG. 1 and illustrating ramps 16sloping downwardly toward the drain channel 40. As can be seen in FIG.3, the fluid inlets 30 allow for the flushing fluid to flow betweenadjacent ones of the modules 12 with the endmost module 12 in theflooring system 10 being connected to the flushing fluid source. Thefluid inlet 30 may be connected to a fluid supply wherein the fluid isdelivered to the hollow passages 28 or to the drain pan 14 via amanifold 94 or other similar plumbing system 96.

The flushing fluid may contain additives such as degreasers which may beinjected into the fluid. The fluid may be water based or may becomprised of alternative liquids. For example, degreaser may be providedor injected into the fluid in order to break down grease that isdeposited on the ramp 16. As can be seen in FIG. 3, the fluid inlets 30may be disposed on the side walls 26 and/or the end walls 42 and may beconcentric with the hollow passage 28 to allow fluid to flowtherebetween. If the hollow passages 28 are not included, the fluidinlets 30 may be connected to a manifold 94 or other plumbing connectionwherein the discharge ports 22 and/or spray nozzles 32 receive flushingfluid therefrom.

Turning now to FIG. 4, shown is an enlarged partial sectional view ofthe module 12 taken from FIG. 3 and illustrating the connectiverelationship of the spray nozzle 32 within the side wall 26. As wasearlier mentioned, the spray nozzle 32 or discharge port 22 may bedisposed above or adjacent to the ramps 16. The discharge ports 22 maybe internally threaded for receiving the spray nozzles 32 which may beincluded in the module 12. The spray nozzles 32 may be discharged fromthe flushing fluid at an elevated pressure level in order to improve theeffectiveness with which the waste products may be washed down the ramps16 toward the drain channel 40. The spray nozzles 32 may be conventionalspray nozzles 32 or alternatively, may be water jets that are integratedinto the manifold 94 without separate spray nozzles 32.

Regarding operation of the discharge ports 22 and/or spray nozzles 32,it is contemplated that flushing fluid may be discharged therefrom viamanual or automatic activation. For automatic activation, a timer 70 maybe included with the flooring system 10 in order to periodically or atscheduled intervals, release flushing fluid into the ramps 16.Furthermore, the spray nozzles 32 and/or discharge ports 22 may beactivated via a thermal sensor such that flushing fluid may bedischarged in case of fire in the facility in which the flooring system10 is installed. Referring still to FIG. 3, the drain pan 14 may includeat least one overflow passage 48 proximate the drain channel 40 to allowfor the flow of flushing fluid and/or liquid waste products betweenadjacent ones of the modules 12. The overflow passages 48 may be formedin the end walls 42 of the drain pan 14 and may be collocated such thatwhen the modules 12 are connected together, the passage is provided viathe overflow passages 48.

As is shown in FIG. 4, the drain pan 14 supports the floor grid 24 via agrid support notch 82 that is formed in the side wall 26. As is shown inFIG. 4, the grid support notch 82 is created via the formation of thehollow passage 28 which extends along the length of the side wall 26.Alternatively, as is shown in the preferred embodiment in FIGS. 9-12,the grid support notch 82 is formed in the side wall 26 with the edge ofthe floor grid 24 resting along the grid support notch 82. A lowerperipheral edge of each one of the floor grids 24 is preferablychamfered or radius to provide a gap between the side wall 26 and thefloor grid 24 (i.e., the grid support notch 82) such that the floor grid24 does not sharply bear against radius corners of the grid supportnotch 82. Furthermore, the lower peripheral edge may be chamfered orradius to provide a gap such that waste products may pass therebetween.

Referring to FIGS. 3-5, each one of the drain pans 14 may comprise orinclude parallel spaced rib members 46 disposed along a length of thedrain pan 14 between the end walls 42. The parallel rib members 46 maybe disposed widthwise under the ramps 16 and drain channel 40 forsupporting the module 12 in an even fashion on the sub-floor such as atile and grout sub-floor that is commonly found in commercial kitchensand other vending establishments. Likewise, as was earlier mentioned,the flooring system 10 may be installed in a variety of applications andindustries including, but not limited to, dairies, meat processingplants, poultry operations, and stables wherein the rib members 46 maybe utilized to support the drain pan 14 and drain channel 40 in an evenmanner.

The drain pan 14 may be formed of any suitable material includingmetallic and non-metallic materials. For metallic materials, it iscontemplated that the drain pan 14 would be formed of stainless steel orotherwise suitable metallic material that is resistant to corrosion andor degradation due to the environmental effects. For non-metallicmaterials, it is contemplated that a polymeric material such aspolyvinyl chloride (PBC) and/or polypropylene may be utilized.

Furthermore, fiberglass may be utilized. In this regard, it iscontemplated that the drain pan 14 may be formed of any material that issuitable and that is compatible with the elevated temperatures that thedrain pan 14 may encounter during washing such as during washing in acommercial dishwasher. The drain pan 14 may be formed as a unitarystructure by any method such as by injection molding. More specifically,it is contemplated that the side walls 26, end walls 42, drain channel40, ramps 16 and rib members 46 as well as grid support notches 82 andother features of the drain pan 14 may be formed via an injectionmolding process so that the drain pan 14 is formed as a single unitarystructure.

During fabrication, it is contemplated that all corners may be radiusedin order to reduce the probabilities of stress cracking that may beinduced by localized stresses in corners. Furthermore, radiused cornersfacilitate cleaning of the drain pan 14 wherein waste products that mayotherwise gather in nooks and crannies and otherwisehard-to-reach-corners, are more easily washed and cleaned. The lowerfloor grids 24 may be radiused to be complementary to any radii formedin the grid support notches 82 above the side walls 26 a. In thismanner, the floor grid 24 lower surface and substantially abuttingcontact with the side wall 26 and/or grid support notch 82.

Turning now to FIG. 5, shown in a transverse sectional view of themodule 12 of the first embodiment taken along line 5-5 of FIG. 1 andillustrating the drain channel 40 sloping downwardly toward the drainoutlet 18. In FIG. 5, the rib members 46 can be seen extendingvertically downwardly from the ramp 16 lower surface. Discharge ports 22can be seen disposed within the side wall 26 and extending along thelength thereof. The discharge ports 22 may be evenly spaced between theend walls 42 although any spacing is contemplated for the dischargeports 22.

The strainer tray 74 is shown disposed above or mounted within the drainchannel 40 which extends from end wall 42 to end wall 42. As was earliermentioned, the strainer tray 74 includes a grate 76 which prevents theentry of solid or semisolid waste products into the drain channel 40which may otherwise fall into the drain outlet 18 resulting in cloggingthereof. As a final measure of protection, a removable drain basket 78may be included in the drain outlet 18 and disposed thereover in orderto prevent solid waste from falling into the drain outlet 18 andclogging down stream features such as a grease trap.

In FIGS. 1-5 as well as in FIGS. 10 and 13, the floor grids 24 are shownformed as an array of spaced parallel grid members 34 that are joinedtogether with the transversely disposed spaced grid members 34. Thespacings of the grid members 34 is preferably such that passage ofsemisolid and liquid waste products is allowed while preventing passageof waste products of a predetermined size. As was earlier mentioned, thefloor grids 24 are sized and configured to span between the side walls26 of the drain pan 14. Similar to the materials used for forming thedrain pan 14, the floor grids 24 may be formed of high strengthmaterial.

For example, the floor grids 24 may be fabricated of fiberglass materialas such material is lightweight to allow easy removal for cleaning ofthe flooring system 10 as well as for cleaning of the floor grid 24itself, as well as highly structurally sound in order to support thepersonnel working and standing thereupon. It will be understood that thefloor grids 24 may be formed of any material and in any configurationsufficient to prevent passage of waste products of a predetermined size.Furthermore, it is contemplated that the material used in fabricatingthe floor grids 24 is compatible with commercial cleaning equipment suchas commercial dishwashers and therefore is capable of surviving elevatedtemperatures. The embodiment of the floor system 10 may be of any sizeand shape. However, it is contemplated that in order to facilitatecleaning of the modules 12, it is contemplated that the width of thedrain pan 14 and floor grid 24 is compatible with cleaning equipment.

Turning now to FIGS. 6 and 7, shown is a second embodiment of aself-cleaning flooring system 10 which, as was earlier mentioned,comprises at least one module 12, but preferably comprises a series ofmodules 12 joined end-to-end. Each one of the modules 12 comprises adrain pan section 66 which is itself comprised of a pair of first andsecond ramp sections 50, 52, and a channel section 54 which is disposedbetween the first and second ramp sections 50, 52. As shown in FIGS. 6and 7, the first ramp section 50 is joined to the second ramp section 52which is interconnected to the channel section 54. The channel section54 is preferably configured to removably interconnect the first andsecond ramp sections 50, 52 together at a lower side portion 58 of eachone of the first and second ramp sections 50, 52.

As was mentioned for the configuration in FIGS. 1-5, the first andsecond ramp sections 50, 52 slope downwardly toward the channel section54. The module 12 shown in FIGS. 6 and 7 is also comprised of at leastone discharge port 22 which is preferably mounted above or adjacent tothe first and/or second ramp sections 50, 52 and which is operative toseparate flushing fluid onto the first and second ramp section 50, 52such that waste products are washed down the first and second rampsections 50, 52 toward the channel section 54 and then from the channelsection 54 toward the drain outlet 18.

The configuration of the flooring system 10 shown in FIGS. 6 and 7 issimilar to that which is shown and described above in FIGS. 1-5 exceptfor the drain pan section 66 being comprised of the first and secondramp sections 50, 52 and channel section 54. Furthermore, the drain pansection 66 shown in FIGS. 6 and 7 may further comprise end plates 64which may be disposed on extreme ends of each one of the modules 12after assembly of consecutive ones of the drain pan sections 66.

For example, as is shown in FIG. 7, the end plate 64 may be secured toan extreme end of one pair of drain pan sections 66 which are adjoinedend-to-end. Another one of the end plates 64 may be adjoined to anopposite end of the module 12 which comprises two of the drain pansections 66. Each one of the drain pan sections 66 includes the channelsection 54 which includes the drain outlet 18 at an end thereof.Preferably, the channel section 54 slopes downwardly toward the drainoutlet 18 but is not necessarily so. For example, it is contemplatedthat the channel section 54 may be formed with no slope and may behorizontally formed.

Each one of the first and second ramp sections 50, 52 may include atleast one rib member 46 which extends from the side wall 26 of the ramp16 section toward the drain channel 40. The rib member 46 is disposedunder the ramp 16 section and is preferably configured to support theramp 16 section above a substrate 88. As can be seen in FIG. 7, thefirst ramp section 50 is of a narrower width than the second rampsection 52 although the first and second ramp sections 50, 52 may beequally configured.

A plurality of discharge ports 22 and/or spray nozzles 32 may bedisposed along upper side portions 56 of the first and second rampsections 50, 52. At least one strainer tray 74 may be mounted above thechannel section 54 and may be configured to prevent waste products of apredetermined size from entering the drain channel 40. Alternatively, aplurality of strainer trays 74 may be connected end-to-end and mountedabove each one of the drain channels 40. Optionally, the strainer tray74 may be omitted such that waste products of any size may be flusheddown the drain outlet 18 and may pass into a holding tank.

Although the drain pan assembly 68 and, more specifically, drain pansections 66 of the second embodiment may be of any size and any shape,it is contemplated that the first ramp section 50 is sized to becompatible with commercially available cleaning equipment as well as thesecond ramp section 52 being likewise sized to facilitate cleaning.Accordingly, the floor grids 24 are preferably sized to be compatiblewith commercial cleaning equipment. In this regard, depending upon themethod of cleaning, it is contemplated that the drain pan sections 66and, hence, the drain pan assemblies 68, may be formed at any size andany shape.

As can be seen in FIG. 7, vertically extending grid supports 60 may beprovided with the first and second ramp sections 50, 52 in order tosupport the floor grids 24. For industries where a person may bestanding on the floor grids 24 for an extended period of time, it iscontemplated that such grid supports 60 may be either limited or alltogether removed in order to allow some degree of flexing in the floorgrid 24 in order to enhance the comfort of personnel standing thereuponfor extended periods of time. As can be seen, one of the drain pansections 66 omits the use of the grid supports 60 while the other one ofdrain pan sections 66 which is joined end-to-end includes the floor gridsupport 60 for exemplary purposes only.

Referring now to FIG. 13, shown is the flooring system 10 in a furtherembodiment wherein the drain pan 14 is formed or cast into a substrate88 such as a concrete substrate 88. More specifically, the flooringsystem 10 shown in FIG. 13 illustrates the drain pan 14 having the sameor similar features as described above for the flooring systems 10 ofFIGS. 1-5 and 9-12. More specifically, the substrate 88 itself forms theshape of the drain pan 14 wherein the substrate 88 itself includes apair of ramps 16 which slope downwardly toward a drain channel 40 withthe drain channel 40 itself sloping downwardly toward the drain outlet18. The drain pan 14 defines the periphery thereof with a perimeterflange 80 being formed around the drain pan 14 for supporting the floorgrid 24 on an upper surface of the substrate 88.

As shown in FIG. 13, the flooring system 10 further includes a manifold94 which may be extended along a portion of the drain pan 14 and whichis formed within a corner of one of the ramps 16. The manifold 94extends along a portion of the ramp 16 and is disposed above the ramp 16in order to provide flushing fluid to the ramp 16 for washing wasteproducts down to the drain channel 40. The flooring system 10 furtherincludes a spray nozzle 32 which may be fluidly connected to themanifold 94 and may be operative to spray flushing fluid down the ramp16 toward the drain channel 40. However, it should be noted that thespray nozzle 32 may be omitted with apertures 38 instead being formed inthe manifold 94 to form ports through which flushing fluid may bedischarged for spraying flushing fluid down the ramps 16.

The cast concrete system which forms the flooring system 10 of thepresent invention may be developed for use in any of the above-mentionedapplications and industries. For example, the cast concrete system maybe used in dairies, meat processing plants, stables and other facilitiesand applications that typically endure heavy wear due to contact withthe heavy animals. Other applications where the cast concrete system forthe flooring system 10 shown in FIG. 13 include poultry operations,emergency rooms, machine shops, clean rooms, printing facilities, foodprocessing plants and other industrial operations. Furthermore, theflooring system 10 of the present invention may be used in transitionareas in animal processing applications.

For example, the flooring system 10 of the present invention may be usedbetween a feed yard and dairy milking stations. In this regard, theflooring system 10 may be installed in certain transition areas and mayinclude an above-ground spray element that could be triggered by hoovesof livestock passing over the flooring system 10. Once the spray elementis triggered, fluid may be sprayed onto the livestock hooves while suchlivestock is entering the dairy milking station such that undesirableresidue (e.g., manure) may be washed from the livestock hooves and intothe flooring system 10 for later retrieval as fertilizer. It iscontemplated that a triggering mechanism may be included with theflooring system 10 to activate the spray element. Such triggeringmechanism may be configured as an infrared beam that is triggered by thelivestock hooves.

Regarding the first above-mentioned application for the cast concretesystem of the flooring system 10, it is contemplated that the manifold94 and/or spray nozzles 32 and/or discharge ports 22 that are typicallyused for washing flushing fluid down the ramps 16, may also be used forspraying animals hooves as they cross over the flooring system 10. Inthis manner, unwanted sediments and manure from stockyards may be washedfrom the hooves of livestock to increase the hygiene and cleanliness ofthe facility into which the flooring system 10 is installed.

As was earlier mentioned, in a dairy, it is contemplated that theflooring system 10 may be configured to spray the hooves of dairy cowswhen brought into a milking facility such as into a rotating milkingsystem. Advantageously, the flooring system 10 as shown in FIG. 13 isinstalled as a cast-in-place system wherein the drain pan 14 itself isformed directly in the substrate 88 such as the concrete substrate 88.Ideally, the drain pan 14 is located in the area in which it is to beinstalled via location of the drain channel 40 flowing down towards thedrain outlet 18. Furthermore, it is contemplated that the floor grids 24for such an application are appropriately sized and configured to handleheavy loads imposed by large livestock such as cattle. In this regard,it is contemplated that the floor grids 24 have an increased thicknesssuch as a two (2) inch thickness for increased load-bearing capacity. Asshown in FIG. 13, floor grid supports 60 may be included to provideadditional support against heavy loads.

As shown in FIG. 13, the drain pan 14 may be formed in the substrate 88using a removable insert which is configured as a male mold thatduplicates the shape of the drain pan 14. FIG. 13 represents one-half ofthe installation with the other half being symmetrically formed aboutthe vertical centerline. However, it is contemplated that theinstallation of the drain pan may be asymmetrical. As was earliermentioned, the male mold will ideally include the features describedabove for the drain pan 14 such as the side wall 26, grid support notch82, ramps 16, and drain channel 40.

The removable insert may preferably be formed as a foam material whichmay be shaped as a single unitary piece of foam or may be shaped as aseries of foam inserts 92 which are individual pieces that collectivelydefine the drain pan 14 shape when installed prior to flooring of thesubstrate 88 such as a concrete substrate 88. Installation of theflooring system 10 is accomplished by initially laying out and locatingthe drain pan 14 with reference to the drain outlet 18 such as the drainchannel 40 the drain pan 14 is roughly centered on the drain outlet 18.

The foam may be placed in the shape of the drain pan 14 after which theconcrete may be poured underneath around the insert. Just prior to orafter curing of the concrete, the foam insert 92 may be removed afterwhich the concrete can proceed to final cure. As can be seen in FIG. 13,a depression may be formed in the ramp 16 to receive the manifold 94which may run lengthwise along the ramp 16. The manifold 94 may beconnected to the flushing fluid source and is operative to sprayflushing fluid down the ramp 16. The grid support notch 82 is formed inthe side wall 26 and is specifically shaped and configured to becomplementary to the thickness of the floor grid 24 for support of thefloor grid 24 thereupon.

Referring now to FIGS. 14 and 15, shown therein is a schematic diagramillustrating a plumbing system 96 as may be connected to the flooringsystem 10 of the present invention. FIG. 14 illustrates the plumbingsystem 96 interconnected to a series of discharge ports 22 and/or spraynozzles 32 installed in a single section of the flooring system 10. Ascan be seen in FIG. 14, the flooring system 10 includes two modules 12connected end-to-end with each module 12 including six discharge ports22 and/or spray nozzles 32. The spray nozzles 32 on one side of theflooring system 10 are connected in series. This schematic diagram ofFIG. 14 illustrates the proper assembly for flooring system 10configurations having anywhere from four to sixteen spray nozzles 32.

FIG. 15 is a schematic diagram of the plumbing system 96 in a furtherembodiment wherein a pair of flooring systems 10 is interconnected tothe plumbing system 96 in parallel. More specifically, the plumbingsystem 96 supplies flushing fluid to a first flooring system 10 and asecond flooring system 10 illustrated in FIG. 15 as being disposed aboveone another. As will be appreciated, the flooring system 10 shown inFIG. 14 is similar to one of the pairs of flooring systems 10illustrated in FIG. 15. It is contemplated that the flushing fluid isprovided by a water supply line 100. Such water supply may be a coldwater supply line 100 having a diameter of about ½ inch in a standardsupply line 100. However, it is contemplated that a ¾ inch diameterwater supply line 100 may be provided with the plumbing system 96.

Minimum static pressure for the water supply line 100 is preferablyabout fifty-five PSI although the water supply may be provided in anypressure level. However, it is preferable that consistent water pressurebe provided to the flooring system 10 and, therefore, depending upon thenumber of spray nozzles 32 and/or discharge ports 22 included within theflooring system 10, a complementary supply line 100 diameter andpressure level should be provided. Along these lines, it is contemplatedthat a pressure source may be included in the plumbing system 96 such asa pressure tank 72 in order to add the appropriate amount of pressure tothe flooring system 10 and plumbing system 96. Even further, theplumbing system 96 may include a pump in order to increase the pressurelevel of the flushing fluid supply.

Referring to FIG. 14, it can be seen that the flushing fluid may beprovided via a supply line 100 which feeds into a shutoff valve 102 thatmay be activated under certain circumstances such as upon loss of power.Also included in the schematic diagram is a check valve 104 which may beinterposed between the pressure tank 72 and the shutoff valve 102 toprevent back flow of flushing fluid. Downstream of the pressure tank 72,a solenoid-controlled-valve 106 may be included.

The valve may be controlled by a timer 70 or by a manual switch. Thesupply line 100 leading to the flooring system 10 may preferably be a ¾inch diameter supply line 100 in order to provide adequate flow offlushing fluid to the flooring system 10. Each one of the flooringsystems 10 may include a header 98 disposed on one end thereof forconnection to the plumbing system 96. As can be seen in FIG. 14, each ofthe spray nozzles 32 on one of the sides of the flooring system 10 ispreferably connect in series. A cap may be provided at the end of eachone of the series of discharge ports 22 and/or spray nozzles 32.

Referring now to FIG. 15, shown is the schematic diagram having a pairof the flooring systems 10 installed in parallel. The plumbing system 96provides flushing fluid, such as water, to the respective ones of theflooring systems 10. The componentry of the schematic diagram shown inFIG. 15 is similar to that described and shown in FIG. 14 above.However, a pair of the solenoid-controlled-valves 106 are included at asplit in the supply line 100. Notably, instead of connecting thedischarge ports 22 and/or spray nozzles 32 in series, the schematicdiagram of FIG. 15 show an alternative arrangement wherein three of thespray nozzles 32 are connected to another three of the spray nozzles 32in parallel with one another. A cap may be provided at an end of eachone of the series of three spray nozzles 32.

Regarding drainage from the drain outlet 18, it is contemplated that athree inch diameter connection be utilized in order to connect a wasteconduit of at least three inches in diameter to each one of the flooringsystems 10. As was earlier mentioned, the drain outlet 18 may lead to agrease trap. Timers 70 and solenoids may optionally be further includedin the flooring systems 10 and may be either manually or autonomouslyoperated. It is contemplated that the timer 70 system may include amanual override in order to allow an operator additional control in thefrequency of spraying of the flushing fluid.

Regarding the pressure tank 72, it is contemplated that each pressuretank 72 may include the capability for containing about six gallons offlushing fluid in order to produce about three to four gallons offlushing fluid that may be pressurized to about thirty to thirty-fivePSI. An additional valve may be included with the pressure tank 72 inorder to provide control over the operating pressure at which thepressure tank 72 operates. As was earlier mentioned, commercialdegreasing agents and other additives may be injected into the plumbingsystem 96 supply line 100 as shown in FIGS. 14 and 15 as required.

The operation of the flooring system 10 will now be described withreference to FIGS. 1-15. The flooring system 10 as shown in FIGS. 1-2may be installed initial by placing the drain pan 14 on the surface towhich it is to be mounted. As was earlier mentioned, such surface mayinclude a concrete flooring substrate 88 or a steel decking arrangementalthough various other configurations are contemplated upon which theflooring systems 10 may be installed. The following connection of theplumbing system 96 as illustrated in FIGS. 14-15, the flushing fluid maybe provided to the pressure tank 72 and then to the series of dischargeports 22 and/or spray nozzles 32 upon activation of the plumbing system96.

Such activation may be autonomous via a timer 70 or via manualactivation by the appropriate personnel. During use, waste products fallthrough the floor grids 24 and pass therethrough landing on the ramps16. At appropriate intervals or when manually activated, flushing fluidis discharged onto the ramps 16 washing the waste products down to thestrainer tray 74 if included. The grating of the strainer tray 74prevents waste products of a predetermined size from entering into thedrain channel 40. The flushing fluid causes the waste products to foldtoward the drain outlet 18 wherein the addition of a drain basket 78further prevents entering of such waste products into the drain outlet18 and clogging of the grease trap.

For the drain pan assembly 68 modules 12 as shown in FIGS. 3-7,following interconnection of the channel section 54 to the first andsecond ramp sections 50, 52 and securing of the end plates 64 uponabutting connection of the drain pan sections 66, the plumbing may thenbe interconnected thereto. Operation and maintenance of the flooringsystem 10 is similar to that which we described below with reference toFIGS. 1-2. For the flooring system 10 illustrated in FIG. 13,installation of the drain pan 14 is effectuated through the use of afoam insert 92 which is set in place after which concrete substrate 88is then poured therearound. Removal of the foam insert 92 and carryingof the concrete substrate 88 results in the creation of the drain pan 14having features similar to that described above for FIGS. 1-7. Followingplacement of the floor grids 24 on the side walls 26, waste products maythen fall through the floor grids 24 and are flushed down into the drainoutlet 18 in a manner similar to that described above.

Maintenance of the flooring system 10 may be effectuated wherein thefloor grids 24 may be removed and may be manually hosed off or washedusing the cleaning equipment available in the facility. For example, ina commercial kitchen, it is contemplated that the floor grids 24 arewashed at each days end in a commercial dishwasher such that such floorgrids 24 are ready for reinstallation. A commercial degreaser may beincluded with the flushing fluid and which may be hand sprayed on thegrates 76 prior to washing in order to remove grease build up. Otherchemicals and additives may be injected in the supply line 100 toprevent grease build up on the ramp 16 and drain channel 40 areas. Inthis same manner, the strainer tray 74 as well as the drain basket 78may be cleaned and checked.

It is contemplated that floor grids 24 of different colors be utilizedin order to easily monitor washing cycles and replacement. For example,one color of the floor grid 24 may be used for even numbered bays whileanother color of a floor grid 24 may be utilized for odd numbered bays.During removal of the floor grids 24, the discharge ports 22 and/orspray nozzles 32 may be adjusted such that the alignment thereof ischecked to ensure that such spray nozzles 32 are spraying evenly downthe ramps 16. Furthermore, various components of the plumbing system 96should be checked such as the pressure tank 72, shutoff valves 102,solenoid-control-valves 106 and supply lines 100.

The above description is given by way of example, and not limitation.Given the above disclosure, one skilled in the art could devisevariations that are within the scope of the invention disclosed herein.Further, the various features of the embodiments disclosed herein can beused alone, or in varying combinations with each other and are notintended to be limited to the specific combination described herein.Thus, the scope of the claims is not to be limited by the illustratedembodiments.

1. A self-cleaning flooring system including at least one module, themodule comprising: a drain pan having at least one ramp and a drainoutlet, the ramp sloping downwardly toward the drain outlet; and atleast one side wall and one end wall forming at least a portion of aperiphery of the drain pan, the end wall having at least one fluidinlet, the side wall having at least one discharge port configured toreceive flushing fluid from the fluid inlet and direct flushing fluiddown the ramp toward the drain outlet.
 2. The self-cleaning flooringsystem of claim 1 comprising a plurality of the modules, each one of themodules being configured to be connectable to one another in horizontalalignment.
 3. The self-cleaning flooring system of claim 1 wherein theside wall includes a hollow passage extending therethrough, the hollowpassage being in fluid communication with the fluid inlet and beingconfigured to deliver flushing fluid to the discharge port.
 4. Theself-cleaning flooring system of claim 1 further including a removabledrain basket positioned adjacent to the drain outlet and being operativeto prevent solid waste from entering the drain outlet.
 5. Theself-cleaning flooring system of claim 1 wherein the module furtherincludes at least one floor grid mounted on the drain pan and beingconfigured to support personnel standing thereupon and permitting wasteproducts to pass therethrough.
 6. The self-cleaning flooring system ofclaim 1 wherein the module further includes at least one strainer traymounted above the drain channel and being configured to prevent wasteproducts of a predetermined size from entering the drain channel.
 7. Theself-cleaning flooring system of claim 1 wherein the drain pan includesa perimeter flange extending around the drain pan periphery and beingconfigured for supporting the drain pan.
 8. The self-cleaning flooringsystem of claim 1 further including at least one pressure tank in fluidcommunication with the fluid inlet and being configured to deliverpressurized flushing fluid thereto.
 9. A self-cleaning flooring systemincluding at least one module, the module comprising: a drain pansection, comprising: a pair of ramp sections; and a channel sectiondisposed between the ramp sections, the channel section being configuredto removably interconnect the ramp sections, the channel section slopingdownwardly toward a drain outlet; wherein each one of the ramp sectionsis oriented to slope downwardly toward the channel section; and at leastone discharge port mounted adjacent to the ramp sections and beingoperative to spray flushing fluid onto the ramp sections such that wasteproducts are washed down the ramp sections toward the channel sectionand from the channel section toward the drain outlet.
 10. Theself-cleaning flooring system of claim 9 wherein the drain outlet islocated adjacent one end of the channel section, the channel sectionsloping downwardly toward the drain outlet.
 11. The self-cleaningflooring system of claim 9 further comprising: at least one end plate;wherein each module comprises a plurality of drain pan sectionsconnected end-to-end and having an end plate mounted on at least one endthereof.
 12. The self-cleaning flooring system of claim 11 wherein theramp sections and the channel section are formed as separate components.13. The self-cleaning flooring system of claim 9 comprising a pluralityof the modules, each one of the modules being configured to beconnectable to one another end-to-end.
 14. The self-cleaning flooringsystem of claim 9 wherein each one of the ramp sections includes atleast one rib member disposed thereunder and being configured to supportthe ramp section above a substrate.
 15. The self-cleaning flooringsystem of claim 9 wherein the module further includes at least one floorgrid mounted on the drain pan section and being configured to supportpersonnel standing thereupon and permitting waste products to passtherethrough.
 16. The self-cleaning flooring system of claim 9 whereinthe module further includes at least one strainer tray mounted above thechannel section and being configured to prevent waste products of apredetermined size from entering the drain channel.
 17. A self-cleaningflooring system formed in a substrate, comprising: a drain pan having apair of ramps sloping downwardly toward a drain channel, the drainchannel sloping downwardly toward a drain outlet, the drain pan defininga periphery with a perimeter flange extending therearound; a manifoldextending along a portion of the drain pan and being disposed above atleast one of the ramps; and a spray nozzle fluidly connected to themanifold and being operative to spray flushing fluid down the ramptoward the drain channel and toward the drain outlet.
 18. The module ofclaim 17 wherein the substrate is concrete.
 19. The module of claim 17wherein the drain pan is formed in the substrate using a removableinsert configured as a male mold.
 20. The module of claim 17 wherein theinsert is a foam material.